Front Fork Removal And Installation - Suzuki Intruder VZ1500 Service Manual

Front Fork Removal and Installation

CAUTION
!
Do not operate the front brake lever and
brake pedal with the front wheel removed.
NOTE
The right and left front forks are installed
symmetrically and therefore the removal
procedure for one side is the same as that for
the other side.
Removal
1) Remove the front wheel assembly. Refer to "Front
Wheel Assembly Removal and Installation in Section
2D (Page 2D-3)".
2) Remove the front fender. Refer to "Exterior Parts
Removal and Installation in Section 9D (Page 9D-
5)".
3) Loosen the front fork upper clamp bolt (1).
NOTE
Slightly loosen the front fork cap bolt (2) to
facilitate later disassembly.
2
4) Loosen the front fork lower clamp bolts (3) and
remove the front fork.
NOTE
Hold the front fork by the hand to prevent
sliding out of the steering stem.
3
Installation
B940H22206002
1) Set the front fork to the front fork lower bracket
temporarily by tightening the lower clamp bolts (1).
2) Tighten the front fork cap bolt (2) to the specified
torque.
Tightening torque
Front fork cap bolt (a): 23 N·m (2.3 kgf-m, 16.5
lbf-ft)
3) Loosen the lower clamp bolts.
4) Set the front fork with the upper surface "T" of the
inner tube positioned 5.0 mm (0.197 in) "a" from the
upper surface of the upper bracket.
1
I940H1220001-01
5) Tighten the front fork lower clamp bolts (1).
Tightening torque
Front fork lower clamp bolt (b): 23 N·m (2.3 kgf-
m, 16.5 lbf-ft)
I940H1220002-02
Front Suspension:
1
2
(a)
"T"
" a "
"a": 5.0 mm (0.197 in)
1
(b)
2B-2
I940H1220003-01
I940H1220004-02
I940H1220005-01